Reactor

ABSTRACT

A reactor includes: a main reactor core including main reaction flow channels through which the raw material fluid flows, and main temperature control flow channels through which the heat medium flows along a flow direction of the raw material fluid flowing in the main reaction flow channel; and a pre-reactor core including pre-reaction flow channels of which an outlet side connects with an inlet side of the main reaction flow channels and through which the raw material fluid flows, and pre-temperature control flow channels of which an inlet side connects with an outlet side of the main reaction flow channels and through which the product serving as the heat medium flows along a flow direction of the raw material fluid flowing in the pre-reaction flow channel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of InternationalApplication No. PCT/JP2016/066993, filed on Jun. 8, 2016, which claimspriority to Japanese Patent Application No. 2015-115655, filed on Jun.8, 2015, the entire contents of which are incorporated by referenceherein.

BACKGROUND 1. Technical Field

Embodiments described herein relate to a reactor for causing a reactionof a raw material fluid (a reaction fluid) by a heat exchange betweenthe raw material fluid and a heat medium to generate a product (areaction product).

2. Description of the Related Art

For example, a reactor used for a hydrogen production process includes areactor core. The reactor core includes reaction flow channels throughwhich a raw material fluid containing methane gas and steam flows, andtemperature control flow channels (heating flow channels) through whicha heat medium such as flue gas flows. In the configuration describedabove, the raw material fluid and the heat medium are supplied to thereactor core, so that the raw material fluid flows through the reactionflow channels and the heat medium flows through the temperature controlflow channels. The heat exchange is then carried out between the rawmaterial fluid and the heat medium to cause a reaction (an endothermicreaction) of the raw material fluid, so as to produce a productcontaining hydrogen and carbon monoxide (refer to Journal of the JapanPetroleum Institute, “Petroleum Refinery Process”; Kodansha, p. 314-318,(May 20, 1998) (Non-Patent Literature 1)). Japanese Translation of PCTInternational Application Publication No. 2006-505387 (PatentLiterature 1) discloses a reactor having the configuration describedabove.

SUMMARY

In order to reduce the time in which a product P remains at extremelyhigh temperature, as high as a temperature range (approximately 400 to700° C.) of metal dusting, for example, the product P needs to be cooledimmediately outside the reactor. The heat of the product P is recoveredby a heat exchange between the product P and water (refrigerant) in aquenching drum (heat recovery boiler) placed outside the reactor, whilesteam serving as part of the raw material fluid is produced as aby-product. As the amount of heat recovered from the product by thequenching drum increases, namely, as the amount of heat recovered fromthe product outside the reactor increases, heat energy (input energy) ofthe heat medium supplied to the reactor increases and an excessiveamount of steam is produced. As a result, the energy efficiency of theentire plant may deteriorate.

It is noted that not only a reactor used for a hydrogen productionprocess but also other types of reactor have the same problems asdescribed above.

One object of the present disclosure is to provide a reactor capable ofimproving energy efficiency in an entire plant.

A reactor according to an aspect of the present disclosure causes areaction of a raw material fluid (a reaction fluid) by a heat exchangebetween the raw material fluid and a heat medium to generate a product(a reaction product), the reactor including: a main reactor coreincluding a main reaction flow channel through which the raw materialfluid flows, and a main temperature control flow channel (a heating flowchannel) through which the heat medium flows along a flow direction ofthe raw material fluid flowing in the main reaction flow channel; and apre-reactor core including a pre-reaction flow channel of which anoutlet side connects with an inlet side of the main reaction flowchannel and through which the raw material fluid flows, and apre-temperature control flow channel (a pre-heating flow channel) ofwhich an inlet side connects with an outlet side of the main reactionflow channel and through which the product serving as the heat mediumflows along a flow direction of the raw material fluid flowing in thepre-reaction flow channel.

As used herein, the term “inlet side” denotes an inlet side of the flowdirection of the raw material fluid, the product or the heat medium, andthe term “outlet side” denotes an outlet side of the flow direction ofthe raw material fluid, the product or the heat medium.

According to the present disclosure, the raw material fluid is suppliedto the pre-reactor core, so that the raw material fluid flows throughthe main reaction flow channels via the pre-reaction flow channels. Inaddition, the heat medium is supplied to the main reactor core, so thatthe heat medium flows through the main temperature control flow channelsalong the flow direction (for example, in the counter or same direction)of the raw material fluid flowing in the main reaction flow channels.The heat exchange is then carried out between the raw material fluid andthe heat medium, so as to increase the temperature of the raw materialfluid sufficient to cause a reaction of the raw material fluid, so as toproduce a product.

As described above, the raw material fluid supplied to the pre-reactorcore flows through the pre-reaction flow channels. The product led outof the main reaction flow channels flows through the pre-temperaturecontrol flow channels along the flow direction (for example, in thecounter or same direction) of the raw material fluid flowing in thepre-reaction flow channels. The heat exchange is then carried outbetween the product serving as a heat medium and the raw material fluid,so as to preheat the raw material fluid in the pre-reactor core and coolthe product.

Since the product can be cooled in the pre-reactor core, the reactor canreclaim the heat to decrease the temperature of the product, so as toprevent an increase in the amount of the heat recovered from the productoutside the reactor.

According to the present disclosure, heat energy (input energy) of theheat medium supplied to the reactor can be reduced, and an excessiveamount of steam generated outside the reactor can be suppressed, so asto improve the energy efficiency in the entire plant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic front view of a reactor according to oneembodiment of the present disclosure.

FIG. 2 is a cross-sectional view taken along line of FIG. 1.

FIG. 3 is a cross-sectional view taken along line III-III of FIG. 1.

FIG. 4 is a cross-sectional view taken along line IV-IV of FIG. 1.

FIG. 5 is a cross-sectional view taken along line V-V of FIG. 1.

FIG. 6 is an enlarged view on arrow VI of FIG. 5.

FIG. 7 is an enlarged cross-sectional view taken along line VII-VII ofFIG. 1.

FIG. 8 is an enlarged view on arrow VIII of FIG. 7

FIG. 9A is a block diagram of the reactor according to one embodiment.

FIG. 9B is a block diagram of a reactor according to another embodiment.

FIG. 10A is a block diagram of the reactor according to one embodiment.

FIG. 10B is a block diagram of a reactor according to anotherembodiment.

DESCRIPTION OF THE EMBODIMENTS

One embodiment and other embodiments of the present disclosure will bedescribed below with reference to the drawings.

As shown in FIG. 1, a reactor 1 according to the present embodimentcauses a reaction of a raw material fluid M by a heat exchange betweenthe raw material fluid M (see FIG. 2) and a heat medium HC (see FIG. 3),so as to produce a product P (see FIG. 2). Before a specificconfiguration of the reactor 1 is described, the reaction of the rawmaterial fluid M is briefly described below.

The reaction of the raw material fluid M includes two types: anendothermic reaction caused by heating the raw material fluid M and anexothermic reaction caused by cooling the raw material fluid M. Examplesof the former reaction (the endothermic reaction) include a steamreforming reaction of methane as represented by the following chemicalequation (1), and a dry reforming reaction of methane as represented bythe following chemical equation (2)

CH₄+H₂O→3H₂+CO   (1)

CH₄+CO₂→2H₂+2CO   (2)

Examples of the latter reaction (the exothermic reaction) include ashift reaction as represented by the following chemical equation (3), amethanation reaction as represented by the following chemical equation(4), and a Fischer tropsch synthesis reaction as represented by thefollowing chemical equation (5).

CO+H₂O→CO₂+H₂   (3)

CO+3H₂→CH₄+H₂O   (4)

(2n+1)H₂+nCO→CnH_(2n+2)+nH₂O   (5)

The reaction of the raw material fluid M is not limited to the steamreforming reaction of methane and the like, and other examples thereofinclude an acetylation reaction, an addition reaction, an alkylationreaction, a dealkylation reaction, a hydrodealkylation reaction, areductive alkylation reaction, an amination reaction, an aromatizationreaction, an arylation reaction, a self-heating reforming reaction, acarbonylation reaction, a decarbonylation reaction, a reductivecarbonylation reaction, a carboxylation reaction, a reductivecarboxylation reaction, a reductive coupling reaction, a condensationreaction, a cracking reaction, a hydrocracking reaction, a cyclizationreaction, a cyclo-oligomerization reaction, a dehalogenation reaction, adimerization reaction, an epoxidation reaction, an esterificationreaction, an exchange reaction, a halogenation reaction, ahydrohalogenation reaction, a homologation reaction, a hydrationreaction, a dehydration reaction, a hydrogenation reaction, adehydrogenation reaction, a hydrocarboxylation reaction, ahydroformylation reaction, a hydrogenolysis reaction, a hydrometalationreaction, a hydrosilylation reaction, a hydrolyzation reaction, ahydroprocessing reaction, an isomerization reaction, a methylationreaction, a demethylation reaction, a substitution reaction, a nitrationreaction, an oxidation reaction, a partial oxidation reaction, apolymerization reaction, a reduction reaction, a reverse water-gas shiftreaction, a sulfonation reaction, a telomerization reaction, atransesterification reaction, and a trimerization reaction.

The heat medium HC used may be high-temperature gas such as flue gas,water, and a refrigerant, and selected as appropriate depending on thereaction type and conditions of the raw material fluid M. For example,when the reaction of the raw material fluid M is a steam reformingreaction of methane, the heat medium HC used is high-temperature gassuch as flue gas. When the reaction of the raw material fluid M is a dryreforming reaction of methane, the heat medium HC used ishigh-temperature gas or the like. When the reaction of the raw materialfluid M is a shift reaction, the heat medium HC used is oil, water(including steam), molten salt, or the like. When the reaction of theraw material fluid M is a methanation reaction, the heat medium HC usedis oil, water (including steam), molten salt, or the like. When thereaction of the raw material fluid M is a Fischer tropsch synthesisreaction, the heat medium HC used is water (including steam) or thelike.

The specific configuration of the reactor 1 is described below. FIG. 2omits the illustration of main catalyst members and pre-catalystmembers. FIG. 3 omits the illustration of main fins and pre-fins. FIG. 5schematically illustrates only part of the main catalyst members andpart of the main fins. FIG. 7 schematically illustrates only part of thepre-catalyst members and part of pre-fins. FIG. 9A and FIG. 9B eachillustrate temperature conditions during operation in a case in whichthe reaction of the raw material fluid is an endothermic reaction. FIG.10A and FIG. 10B each illustrate temperature conditions during operationin a case in which the reaction of the raw material fluid is anexothermic reaction.

As shown in FIG. 1 and FIG. 5, the reactor 1 includes a main reactorcore 3 for causing a reaction of the raw material fluid M to produce aproduct P. The main reactor core 3 is installed at an appropriateposition with a plurality of supporting pillars 5. The main reactor core3 includes a plurality of (multiple) rectangular main reactor structures(main reactor members) 7 for providing a reaction space for the rawmaterial fluid M (for causing a reaction of the raw material fluid M),and a plurality of (multiple) rectangular main temperature controlstructures (main temperature control members) 9. The main reactorstructures 7 and the main temperature control structures 9 arealternately stacked in the vertical direction (the height direction ofthe reactor 1 (the Z direction)). The specific configuration of each ofthe main reactor structures 7 and the main temperature controlstructures 9 is described below.

FIG. 2 to FIG. 5 illustrate the main reactor structure 7 made of an ironalloy such as stainless steel, or a nickel alloy such as Inconel alloy625, Inconel alloy 617, and Haynes alloy 230 (examples of heat-resistantalloys). A plurality of main reaction flow channels 11 through which theraw material fluid M flows in the left direction are arranged at regularintervals in the front-rear direction (the depth direction of thereactor 1 (the X direction)) on one surface (the upper surface) of themain reactor structure 7. The respective main reaction flow channels 11extend in the lateral direction (the width direction of the reactor 1(the Y direction)), and have a channel length (a length in the lateraldirection) which is set at approximately several tens of centimeters inthe present embodiment, for example. The right side of the main reactionflow channels 11 corresponds to the inlet side (the introduction side)of the flow direction of the raw material fluid M. The left side of themain reaction flow channels 11 corresponds to the outlet side (theleading-out side) of the flow direction of the raw material fluid M orthe product P, and is open so as to lead the raw material fluid M out ofthe main reaction flow channels 11.

The respective main reaction flow channels 11 have a rectangular shapein cross section. For example, in the present embodiment, the width ofthe main reaction flow channels 11 is set at 2 to 60 mm, and the heightof the main reaction flow channels 11 is set at 1 to 10 mm, preferably 4to 8 mm.

A raw material introduction port 13 for introducing the raw materialfluid M therefrom is provided on the right side on the front surface ofthe main reactor structure 7. A main reaction connection flow channel 15by which the raw material introduction port 13 connects with the pluralmain reaction flow channels 11 on the right side (on the inlet side) isprovided on the right side on one surface of the main reactor structure7. The main reaction connection flow channel 15 extends in thefront-rear direction.

The main reactor core 3 is schematically illustrated. For example, themain reactor core 3 includes several tens of main reactor structures 7and several tens of main reaction flow channels 11 in each main reactorstructure 7 in the present embodiment. The number of the main reactionconnection flow channel 15 may be changed depending on the number of themain reaction flow channels 11. The maximum pressure in the respectivemain reaction flow channels 11 when the reactor 1 is in operation is setat a predetermined level in a range of 0.0 to 20.0 MPaG which variesdepending on the reaction type and conditions of the raw material fluidM.

The main temperature control structure 9 is made of the same material asthe main reactor structure 7. A plurality of main temperature controlflow channels (heating flow channels) 17 through which the heat mediumHC flows along the flow direction of the raw material fluid M in themain reaction channels 11 (in the right direction opposite to the flowdirection (in the counter flow direction)) are arranged at regularintervals in the front-rear direction on one surface of the maintemperature control structure 9. The flow direction of the heat mediumHC with respect to the flow direction of the raw material fluid M in themain reaction channels 11 includes not only the exactly defineddirection but also a direction allowing an inclination to some extentunder the conditions in Which the effects of the present embodiment canbe achieved. The respective main temperature control flow channels 17extend in the lateral direction, and have a channel length (a length inthe lateral direction) which is set at approximately several tens ofcentimeters in the present embodiment, for example. The left side of themain temperature control flow channels 17 corresponds to the inlet side(the introduction side) of the flow direction of the heat medium HC. Theright side of the main temperature control flow channels 17 correspondsto the outlet side (the leading-out side) of the flow direction of theheat medium HC, and is open so as to lead the heat medium HC out of themain temperature control flow channels 17.

The respective main temperature control flow channels 17 have arectangular shape in cross section. For example, in the presentembodiment, the width of the main temperature control flow channels 17is set at 2 to 60 mm, and the height of the temperature control flowchannels 17 is set at 1 to 10 mm, preferably 4 to 8 mm. The maintemperature control flow channels 17 are opposed to the correspondingmain reaction flow channels 11 in the vertical direction.

A heat medium introduction port 19 for introducing the heat medium HCtherefrom is provided on the left side on the front surface of the maintemperature control structure 9. A main temperature control connectionflow channel 21 by which the heat medium introduction port 19 connectswith the plural main temperature control flow channels 17 on the leftside (on the inlet side) is provided on the left side on one surface ofthe main temperature control structure 9. The main temperature controlconnection flow channel 21 extends in the front-rear direction.

As described above, the main reactor core 3 is schematicallyillustrated. For example, the main reactor core 3 includes several tensof main temperature control structures 9 and several tens of maintemperature control flow channels 17 in each main temperature controlstructure 9 in the present embodiment. The number of the maintemperature control connection flow channel 21 may be changed dependingon the number of the main temperature control flow channels 17. Themaximum pressure in the respective main temperature control flowchannels 17 when the reactor 1 is in operation is set at a predeterminedlevel in a range of 0.0 to 20.0 MPaG which varies depending on thereaction type and conditions of the raw material fluid M.

As shown in FIG. 5, the lowermost main temperature control structure 9is thicker than the other main temperature control structures 9. Therespective main temperature control structures 9 other than thelowermost main temperature control structure 9 have the same dimensionsas the main reactor structures 7. The uppermost main temperature controlstructure 9 is provided with a main lid structure (a main lid member) 23having a rectangular plate shape and covering the main temperaturecontrol flow channels 17.

As shown in FIG. 5 and FIG. 6, a main catalyst member 25 supporting acatalyst for promoting the reaction of the raw material fluid M isremovably provided in the respective main reaction channels 11. The maincatalyst member 25 is made of stainless steel, for example, and extendsin the lateral direction. The main catalyst member 25 has a wave-likeshape in cross section, for example. The catalyst is selected asappropriate depending on the type of the reaction of the raw materialfluid M. When the reaction of the raw material fluid M is a steamreforming reaction of methane, the catalyst used is one or more kinds ofmetal selected from nickel (Ni), platinum (Pt), ruthenium (Ru), rhodiuni(Rh), palladium (Pd), cobalt (Co), rhenium (Re), and iridium (Ir). Thecatalyst may be applied on the respective main reaction channels 11 (asan example of supporting methods), instead of the catalyst member 25removably provided in the respective main reaction channels 11.

A pair of main fins (main baffles) 27 is removably provided in therespective main temperature control flow channels 17. The paired fins 27are laid on top of each other in the vertical direction. The respectivefins 27 are made of stainless steel, for example, and extend in thelateral direction. The respective fins 27 have a wave-like shape incross section, for example.

As shown in FIG. 1 and FIG. 7, a pre-reactor core 29 for preliminarilycausing a reaction of part of the raw material fluid M is aligned on theleft side of the main reactor core 3 (on one side in the width directionof the reactor 1) via a plurality of supporting pillars 31. Thepre-reactor core 29 is removably integrated with (attached to) the mainreactor core 3. The pre-reactor core 29 is not necessarily integratedwith the main reactor core 3 and may be separated from the main reactorcore 3. When the pre-reactor core 29 is separated from the main reactorcore 3, a connection member connecting the outlet side of pre-reactionflow channels 37 and the inlet side of the main reaction channels 11 isprovided, so as to supply the raw material fluid from the pre-reactionflow channels 37 to the main reaction flow channels 11. In addition, aconnection member connecting the outlet side of the main reaction.channels 11 and the inlet side of pre-temperature control flow channels43 is provided, so as to supply the raw material fluid from the mainreaction flow channels 11 to the pre-temperature control flow channels43.

The pre-reactor core 29 includes a plurality of (multiple) rectangularpre-reactor structures 33 for providing a reaction space for the rawmaterial fluid M and a plurality of (multiple) rectangularpre-temperature control structures 35, the pre-reactor structures 33 andthe pre-temperature control structures 35 being alternately stacked inthe vertical direction. The specific configuration of each of thepre-reactor structures 33 and the pre-temperature control structures 35is described below.

As shown in FIG. 2, FIG. 4, and FIG. 7, the pre-reactor structure 33 ismade of the same material as the main reactor structure 7. The pluralpre-reaction flow channels 37 through which the raw material fluid Mflows in the right direction are arranged at regular intervals in thefront-rear direction on one surface (the upper surface) of thepre-reactor structure 33. The respective pre-reaction flow channels 37extend in the lateral direction (the width direction of the reactor 1),and have a channel length (a length in the lateral direction) which isset at approximately several tens of centimeters in the presentembodiment, for example. The left side of the pre-reaction flow channels37 corresponds to the inlet side (the introduction side) of the flowdirection of the raw material fluid M, and is open so as to introducethe raw material fluid M therefrom. The right side of the pre-reactionflow channels 37 corresponds to the outlet side (the leading-out side)of the flow direction of the raw material fluid M.

The respective pre-reaction flow channels 37 have a rectangular shape incross section. For example, in the present embodiment, the width of thepre-reaction flow channels 37 is set at 2 to 60 mm, and the height ofthe pre-reaction flow channels 37 is set at 1 to 10 mm, preferably 4 to8 mm.

A raw material leading-out port 39 for leading the raw material fluid M(including part of the product P) out of the pre-reactor structure 33 isprovided on the right side on the front surface of the pre-reactorstructure 33. A pre-reaction connection flow channel 41 by which the rawmaterial leading-out port 39 connects with the plural pre-reaction flowchannels 37 on the right side (on the outlet side) is provided on theright side on one surface of the pre-reactor structure 33. Thepre-reaction connection flow channel 41 extends in the front-reardirection.

The pre-reactor core 29 is schematically illustrated. For example, thepre-reactor core 29 includes several tens of pre-reactor structures 33and several tens of pre-reaction flow channels 37 in each pre-reactorstructure 33 in the present embodiment. The number of the pre-reactionconnection flow channel 41 may be changed depending on the number of thepre-reaction flow channels 37. The maximum pressure in the respectivepre-reaction flow channels 37 when the reactor 1 is in operation is setat a predetermined level in a range of 0.0 to 20.0 MPaG which variesdepending on the reaction type and conditions of the raw material fluidM.

The pre-temperature control structure 35 is made of the same material asthe main reactor structure 7. The plural pre-temperature control flowchannels 43 through which the product P serving as a heat medium HCflows in the left direction (in the counter flow direction) opposite tothe flow direction of the raw material fluid M flowing in thepre-reaction flow channels 37 are arranged at regular intervals in thefront-rear direction on one surface (the upper surface) of thepre-temperature control structure 35. The respective pre-temperaturecontrol flow channels 43 extend in the lateral direction, and have achannel length (a length in the lateral direction) which is set atapproximately several tens of centimeters in the present embodiment, forexample. The right side of the pre-temperature control flow channels 43corresponds to the inlet side (the introduction side) of the flowdirection of the heat medium HC, and is open so as to introduce theproduct P serving as a heat medium HC. The left side of thepre-temperature control flow channels 43 corresponds to the outlet side(the leading-out side) of the flow direction of the heat medium HC. Theinlet side (the right side) of the pre-temperature control flow channels43 is directly connected to (directly connects with) the outlet side(the left side) of the corresponding main reaction channels 11. When thepre-reactor core 29 is separated from the main reactor core 3, the inletside of the pre-temperature control flow channels 43 connects with theoutlet side of the corresponding main reaction channels 11 by aconnection member (not shown).

The respective pre-temperature control flow channels 43 have arectangular shape in cross section. For example, in the presentembodiment, the width of the pre-temperature control flow channels 43 isset at 2 to 60 mm, and the height of the pre-temperature control flowchannels 43 is set at 1 to 10 mm, preferably 4 to 8 mm. Thepre-temperature control flow channels 43 are opposed to thecorresponding pre-reaction flow channels 37 in the vertical direction.

A product leading-out port 45 for leading the product P out of thepre-temperature control structure 35 is provided on the left side on thefront surface of the pre-temperature control structure 35. Apre-temperature control connection flow channel 47 by which the productleading-out port 45 connects with the plural pre-temperature controlflow channels 43 on the left side (on the outlet side) is provided onthe left side of one surface of the pre-temperature control structure35. The pre-temperature control connection flow channel 47 extends inthe front-rear direction.

As described above, the pre-reactor core 29 is schematicallyillustrated. For example, the pre-reactor core 29 includes several tensof pre-temperature control structures 35 and several tens ofpre-temperature control flow channels 43 in each pre-temperature controlstructure 35 in the present embodiment. The number of thepre-temperature control connection flow channel 47 may be changeddepending on the number of the pre-temperature control flow channels 43.The maximum pressure in the respective pre-temperature control flowchannels 43 when the reactor 1 is in operation is set at a predeterminedlevel in a range of 0.0 to 20.0 MPaG which varies depending on thereaction type and conditions of the raw material fluid M.

As shown in FIG. 7, the lowermost pre-temperature control structure 35is thicker than the other pre-temperature control structures 35. Therespective pre-temperature control structures 35 other than thelowermost pre-temperature control structure 35 have the same dimensionsas the pre-reactor structures 33. The uppermost pre-temperature controlstructure 35 is provided with a pre-lid structure (a pre-lid member) 49having a rectangular plate shape and covering the pre-temperaturecontrol connection flow channels 43.

As shown in FIG. 7 and FIG. 8, a pre-catalyst member 51 supporting acatalyst for promoting the reaction of the raw material fluid M isremovably provided in the respective pre-reaction flow channels 37. Thepre-catalyst member 51 is made of the same material as the main catalystmember 25, and extends in the lateral direction. The pre-catalyst member51 has a wave-like shape in cross section, for example. The catalyst maybe applied on the respective pre-reaction flow channels 37, instead ofthe pre-catalyst member 51 removably provided in the respectivepre-reaction flow channels 37.

A pair of pre-fins (pre-fin baffles) 53 is removably provided in therespective pre-temperature control flow channels 43. The paired pre-fins53 are laid on top of each other in the vertical direction. Therespective pre-fins 53 are made of the same material as the main fins27, and extend in the lateral direction. The respective pre-fins 53 havea wave-like shape in cross section, for example.

As shown in FIG. 1 and FIG. 2, a first raw material introduction chamber(an example of hollow raw material introduction members) 55 having adome-like shape for introducing the raw material fluid M into therespective pre-reaction flow channels 37 is removably provided on theleft side of the pre-reactor core 29. The first raw materialintroduction chamber 55 connects with the respective pre-reaction flowchannels 37. The first raw material introduction chamber 55 is providedin the middle with a first raw material supply port 57. The first rawmaterial supply port 57 is connected to a raw material supply source(not shown) for supplying the raw material fluid M.

A raw material exhaust chamber (an example of hollow product exhaustmembers) 59 having a box shape for collecting and exhausting the rawmaterial fluid M led out of the respective raw material leading-outports 39 is provided on the right side on the front surface of thepre-reactor core 29. The raw material exhaust chamber 59 extends in thevertical direction and connects with the respective raw materialleading-out ports 39. The raw material exhaust chamber 59 is provided inthe middle with a raw material exhaust port 61.

A second raw material introduction chamber (an example of hollow rawmaterial introduction members) 63 having a box shape for introducing theraw material fluid M into the respective main reaction channels 11 isprovided on the right side of the main reactor core 3. The second rawmaterial introduction chamber 63 extends in the vertical direction andconnects with the respective raw material introduction ports 13. Thesecond raw material introduction chamber 63 is provided in the middlewith a second raw material supply port 65. A connection member 67 bywhich the outlet side of the respective pre-reaction flow channels 37connects with the inlet side of the respective main reaction channels 11via the raw material exhaust chamber 59 and the second raw materialintroduction chamber 63, is provided between the raw material exhaustport 61 and the second raw material supply port 65.

A product exhaust chamber (an example of hollow product exhaust members)69 having a box shape for collecting and exhausting the product P ledout of the respective product leading-out ports 45 is provided on theleft side on the front surface of the pre-reactor core 29. The productexhaust chamber 69 extends in the vertical direction and connects withthe respective product leading-out ports 45. The product exhaust chamber69 is provided in the middle with a product exhaust port 71. The productexhaust port 71 is connected to another treatment device (not shown) forsubjecting the product P to aftertreatment.

As shown in FIG. 1 and FIG. 3, a heat medium introduction chamber (anexample of hollow heat medium introduction members) 73 having a boxshape for introducing the heat medium into the respective heat mediumintroduction ports 19 is provided on the left side on the rear surface(the back surface) of the main reactor core 3. The heat mediumintroduction chamber 73 extends in the vertical direction and connectswith the respective main temperature control flow channels 17. A heatmedium supply port 75 is provided at the upper portion of the heatmedium introduction chamber 73. The heat medium supply port 75 isconnected to a heat medium supply source 77 for supplying the heatmedium HC via a supply pipe 79. A heat medium adjustment device 81 suchas a heat medium adjustment valve is installed in the middle of thesupply pipe 79. The heat medium adjustment device 81 adjusts a flow rateor temperature of the heat medium HC supplied to the respective maintemperature control flow channels 17 so as to set the temperature of therespective main reaction channels 11 on the outlet side (the temperatureof the product P) at a target temperature. The heat medium adjustmentdevice 81 may be omitted when the product P does not contain carbonmonoxide (CO).

A heat medium exhaust chamber (an example of hollow heat medium exhaustmembers) 83 having a dome-like shape for collecting and exhausting theheat medium led out of the respective main temperature control flowchannels 17 is removably provided on the right side of the main reactorcore 3. The heat medium exhaust chamber 83 connects with the respectivemain temperature control flow channels 17. The heat medium exhaustchamber 83 is provided in the middle with a heat medium exhaust port 85.The heat medium exhaust port 85 is connected to a heat medium recoveringapparatus (not shown) for recovering the heating fluid HC.

Next, the effects of the present embodiment and a method of producing aproduct according to the present embodiment including a heat exchangestep and a pre-heat exchange step are described below. In the followingexplanations, the reaction of the raw material fluid M by the reactor 1is an endothermic reaction for illustration purposes.

Heat Exchange Step (Main Reaction Step)

The raw material fluid M is supplied to the first raw materialintroduction chamber 55 (on the pre-reactor core 29 side) from the rawmaterial supply source via the first raw material supply port 57, sothat the raw material fluid M is introduced to the respectivepre-reaction flow channels 37. The raw material fluid M introduced flowsthrough the respective pre-reaction flow channels 37 in the rightdirection of the drawings and is led to the raw material exhaust chamber59 through the respective raw material leading-out ports 39. The rawmaterial fluid M led to the raw material exhaust chamber 59 is thensupplied to the second raw material introduction chamber 63 through theraw material exhaust port 61, the connection member 67, and the secondraw material supply port 65.

The raw material fluid M supplied to the second raw materialintroduction chamber 63 is introduced to the respective main reactionchannels 11 through the respective raw material introduction ports 13and flows through the respective main reaction channels 11 in the leftdirection of the drawings. Namely, the raw material fluid M supplied tothe first raw material introduction chamber 55 is introduced to therespective main reaction channels 11 via the respective pre-reactionflow channels 37, the connection member 67, and the like and flowsthrough the respective main reaction channels 11 in the left directionof the drawings. In addition, the heat medium HC is supplied to the heatmedium introduction chamber 73 (on the main reactor core 3 side) fromthe heat medium supply source 77 (outside the reactor 1), so that theheat medium HC is introduced to the respective main temperature controlflow channels 17 through the respective heat medium introduction ports19 and flows through the respective main temperature control flowchannels 17 in the right direction of the drawings. The heat exchange isthen carried out between the raw material fluid M in the main reactionchannels 11 and the heat medium HC in the corresponding main temperaturecontrol flow channels 17, so as to heat the raw material fluid M. Inassociation with the reaction promotion due to the catalyst supported inthe respective main catalyst members 25, the temperature of the rawmaterial fluid M is increased to a reaction temperature, so as to causea reaction (an endothermic reaction) of the raw material fluid M andproduce the product P, which is led out of the outlet side of therespective main reaction channels 11 accordingly. The heat medium HCused for the heat exchange is led into the heat medium exhaust chamber83 from the outlet side of the respective main temperature control flowchannels 17, so as to be exhausted from the heat medium, exhaust port 85toward the heat medium recovering apparatus outside the reactor 1.

Pre-heat Exchange Step (Pre-reaction Step)

As described above, the raw material fluid M supplied to the first rawmaterial introduction chamber 55 is introduced to the respectivepre-reaction flow channels 37, and flows through the respectivepre-reaction flow channels 37 in the right direction of the drawings.The product P led out of the respective main reaction channels 11 isintroduced to the respective pre-temperature control flow channels 43,and flows through the respective pre-temperature control flow channels43 in the left direction of the drawings. The heat exchange is thencarried out between the raw material fluid M in the pre-reaction flowchannels 37 and the product P serving as a heat medium HC in thecorresponding pre-temperature control flow channels 43, so as to preheatthe raw material fluid M and cool the product P in the pre-reactor core29. In association with the reaction promotion due to the catalystsupported in the respective pre-catalyst members 51, part of the rawmaterial fluid M can be preliminarily reacted, and the temperature ofthe product P can be cooled.

The product P serving as a heat medium HC used for the heat exchange isled into the product exhaust chamber 69 through the respective productleading-out ports 45, so as to be exhausted from the product exhaustport 71 toward the other treatment device outside the reactor 1.

FIG. 9A illustrates temperature conditions when the reactor 1 is inoperation (temperature conditions of the raw material fluid M, theproduct P, and the heat medium HC). In the pre-reactor core 29, thetemperature of the raw material fluid M is increased from 350° C. to600° C. through the heat exchange with the product P serving as a heatmedium HC. In the main reactor core 3, the reaction (the endothermicreaction) of the raw material fluid M is caused through the heatexchange with the heat medium HC, so as to produce the product P at atemperature of 850° C. The heat load (the amount of heat consumed) inthe pre-reactor core 29 corresponds to 30% of the heat load in theentire reactor 1, and the heat load in the main reactor core 3corresponds to 70% of the entire reactor 1.

The length of at least one side of each of the main reaction channels 11and the main temperature control flow channels 17 in cross section isset at several millimeters, and the specific surface area of each of themain reaction channels 11 and the main temperature control flow channels17 per unit of volume is large. The pair of the main fins 27 cangenerate a turbulent flow of the heat medium HC in the respective maintemperature control flow channels 17 and increase the heat transfer areainside the respective main temperature control flow channels 17.Accordingly, the heat exchange performance (the efficiency of heattransfer) between the raw material fluid M in the main reaction channels1.1 and the heat medium HC in the corresponding main temperature controlflow channels 17 is improved.

Similarly, the length of at least one side of each of the pre-reactionflow channels 37 and the pre-temperature control flow channels 43 incross section is set at several millimeters, and the specific surfacearea of each of the pre-reaction flow channels 37 and thepre-temperature control flow channels 43 per unit of volume is large.The pair of the pre-fins 53 can generate a turbulent flow of the productP serving as a heat medium HC in the respective pre-temperature controlflow channels 43 and increase the heat transfer area inside therespective pre-temperature control flow channels 43. Accordingly, theheat exchange performance between the raw material fluid M in thepre-reaction flow channels 37 and the heat medium HC in thecorresponding pre-temperature control flow channels 43 is improved.

Since the product P can be cooled in the pre-reactor core 29, thereactor 1 can recover the heat to decrease the temperature of theproduct P, so as to sufficiently prevent an increase in the amount ofthe heat recovered from the product P outside the reactor 1.Particularly, since the heat exchange performance between the rawmaterial fluid M in the pre-reaction flow channels 37 and the heatmedium HC in the corresponding pre-temperature control flow channels 43is improved, the reactor 1 can recover the heat of the product P in ashort period of time.

In addition to the effects described above, the heat medium adjustmentdevice 81 adjusts the flow rate or temperature of the heat medium HCsupplied to the respective main temperature control flow channels 17,while monitoring the temperature on the outlet side of the respectivemain reaction channels 11. Thus, the temperature on the outlet side ofthe respective main reaction channels 11 (the temperature of the productP) can be set at a target temperature.

Since the main reactor core 3 can be separated from the pre-reactor core29, the main catalyst members 25 can easily be replaced from the leftside of the main reactor core 3 when the catalyst supported on the maincatalyst members 25 is deteriorated. The pre-fins 53 can also easily bereplaced from the right side of the pre-reactor core 29 when thepre-fins 53 are damaged. Since the heat medium exhaust chamber 83 isremovably attached to the main reactor core 3 on the right side, themain fins 27 can easily be replaced from the right side of the mainreactor core 3 when the main fins 27 are damaged. Since the first rawmaterial introduction chamber 55 is removably attached to thepre-reactor core 29 on the left side, the pre-catalyst members 51 caneasily be replaced from the left side of the pre-reactor core 29 whenthe catalyst supported on the pre-catalyst members 51 is deteriorated.

According to the present embodiment, the reactor 1 can recover the heatof the product P in a short period of time, so as to sufficientlyprevent an increase in the amount of the heat recovered from the productP outside the reactor 1. Accordingly, heat energy (input energy) of theheat medium HC supplied to the main reactor core 3, namely, to thereactor 1 can be decreased and an excessive amount of steam generatedoutside the reactor 1 can be suppressed, so as to improve the energyefficiency of the entire plant.

Since the heat exchange performance between the raw material fluid M inthe pre-reaction flow channels 37 and the product P serving as a heatmedium HC in the corresponding pre-temperature control flow channels 43is improved, the reaction speed of the raw material fluid M and theyield of the product P can be increased.

Since the temperature on the outlet side of the respective main reactionchannels 11 can be set at a target temperature, metal dusting in relatedfacilities (not shown) such as the other treatment device describedabove due to the product P can sufficiently be prevented even when theproduct P contains carbon monoxide (CO).

Since the main catalyst members 25 and the pre-fins 53 can easily bereplaced from the left side of the main reactor core 3 and the rightside of the pre-reactor core 29, respectively, the performance ofmaintenance of the reactor 1 can be improved.

FIG. 10A illustrates temperature conditions when the reactor 1 is inoperation in a case in which the reaction of the raw material fluid M isan exothermic reaction.

Other Embodiments

The configuration of a reactor 1A according to another embodiment shownin FIG. 9B different from the configuration of the reactor 1 accordingto the embodiment described above (refer to FIG. 1 and FIG. 9A) isbriefly described below.

Instead of the configuration in which the inlet side of thepre-temperature control flow channels 43 is directly connected to theoutlet side (the right side) of the corresponding main reaction flowchannels 11, the outlet side (the right side) of the pre-reaction flowchannels 37 is directly connected to the inlet side (the left side) ofthe corresponding main reaction flow channels 11. While FIG. 1 and FIG.9A illustrate the reactor 1 including the connection member 67 by whichthe outlet side of the pre-reaction flow channels 37 connects with theinlet side of the main reaction flow channels 11, FIG. 9B illustratesthe reactor LA including a connection member 87 by which the outlet sideof the main reaction flow channels 11 connects with the inlet side ofthe pre-temperature control flow channels 43. The product P led out ofthe respective main reaction flow channels 11 is introduced to thepre-temperature control flow channels 43 via the connection member 87.

FIG. 9B illustrates temperature conditions when the reactor core 1A isin operation in the case in which the reaction of the raw material fluidM is an endothermic reaction. FIG. 10B illustrates temperatureconditions when the reactor 1A is in operation in the case in which thereaction of the raw material fluid M is an exothermic reaction.

Other embodiments can also achieve the same operations and effects asthe embodiment described above.

The present disclosure is not intended to be limited to the descriptionof the embodiments described above, and may be applicable to variousmodes. For example, more than one pre-reactor core 29 may be provided.The flow direction of the heat medium. HC flowing in the maintemperature control flow channels 17 may be changed from the directionopposite to the flow direction of the raw material fluid M flowing inthe main reaction flow channels 11 so that the heat medium HC flows inthe same direction. The flow direction of the product P serving as aheat medium HC flowing in the pre-temperature control flow channels 43may be changed from the direction opposite to the flow direction of theraw material fluid M flowing in the pre-reaction flow channels 37 sothat the product P flows in the same direction. The case in which theflow direction of the heat medium HC flowing in the main temperaturecontrol flow channels 17 is the same as the flow direction of the rawmaterial fluid M flowing in the main reaction flow channels 11 isillustrated below.

For example, the raw material fluid M subjected to an exothermicreaction to produce a product is supplied to the main temperaturecontrol flow channels 17. The raw material fluid HC subjected to anendothermic reaction to produce a product is supplied to the mainreaction flow channels 11. As the raw material fluid M flows through themain temperature control flow channels 17, the exothermic reaction iscaused to generate heat of reaction. The heat of reaction thus generatedcan be used for a heat source for the endothermic reaction to be causedin the main reaction flow channels 11. Accordingly, the heat can be usedeffectively.

For example, when the raw material fluid M is reacted at a constanttemperature in the main reaction flow channels 11, a refrigerant as araw material fluid HC is introduced to flow through the main temperaturecontrol flow channels 17 in order to keep the inlet temperature so asnot to deactivate the catalyst. Accordingly, the raw material fluid Mcan be reacted constantly in the main reaction flow channels 11 whileheat is removed so as not to deactivate the catalyst.

It should be noted that the present disclosure includes variousembodiments which are not disclosed herein. Therefore, the scope of thepresent disclosure is defined only by the matters specified according tothe claims reasonably derived from the description described above.

What is claimed is:
 1. A reactor for causing a reaction of a raw material fluid by a heat exchange between the raw material fluid and a heat medium to generate a product, the reactor comprising: a main reactor core including a main reaction flow channel through which the raw material fluid flows, and a main temperature control flow channel through which the heat medium flows along a flow direction of the raw material fluid flowing in the main reaction flow channel; and a pre-reactor core including a pre-reaction flow channel of which an outlet side connects with an inlet side of the main reaction flow channel and through which the raw material fluid flows, and a pre-temperature control flow channel of which an inlet side connects with an outlet side of the main reaction flow channel and through which the product serving as the heat medium flows along a flow direction of the raw material fluid flowing in the pre-reaction flow channel.
 2. The reactor according to claim 1, further comprising a connection member connecting the outlet side of the pre-reaction flow channel and the inlet side of the main reaction flow channel.
 3. The reactor according to claim 1, further comprising a connection member connecting the outlet side of the main reaction flow channel and the inlet side of the pre-temperature control flow channel.
 4. The reactor according to claim 2, wherein the inlet side of the pre-temperature control flow channel is directly connected to the outlet side of the main reaction flow channel.
 5. The reactor according to claim 3, wherein the outlet side of the pre-reaction flow channel is directly connected to the inlet side of the main reaction flow channel.
 6. The reactor according to claim 1, wherein the main reactor core includes: main reactor structures each provided with the main reaction flow channel; and main temperature control structures alternately stacked on the main reactor structures and each provided with the main temperature control flow channel, and the pre-reactor core includes: pre-reactor structures each provided with the pre-reaction flow channel; and pre-temperature control structures alternately stacked on the pre-reactor structures and each provided with the pre-temperature control flow channel.
 7. The reactor according to claim 1, wherein a catalyst for promoting the reaction of the raw material fluid is supported in each of the main reaction flow channel and the pre-reaction flow channel.
 8. The reactor according to claim 7, wherein a main catalyst member supporting the catalyst is removably provided in the main reaction flow channel, and a pre-catalyst member supporting the catalyst is removably provided in the pre-reaction flow channel.
 9. The reactor according to claim 1, wherein a main fin is removably provided in the main temperature control flow channel, and a pre-fin is removably provided in the pre-temperature control flow channel.
 10. The reactor according to claim 1, further comprising a heat medium adjustment device for adjusting a flow rate or a temperature of the heat medium supplied to the main temperature control flow channel.
 11. The reactor according to claim 1, wherein the pre-reactor core is removably integrated with the main reactor core.
 12. The reactor according to claim I, wherein the heat medium flows through the main temperature control flow channel in a direction opposite to or identical to the flow direction of the raw material fluid flowing in the main reaction flow channel.
 13. The reactor according to claim 1, wherein the product serving as the heat medium flows through the pre-temperature control flow channel in a direction opposite to or identical to the flow direction of the raw material fluid flowing in the pre-reaction flow channel. 